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Moulded Components


Moulded Components

Utilising our extensive injection moulding, compression moulding and transfer moulding facilities we convert the widest range of melt fluoropolymers and advanced engineering thermoplastics into precision component parts. In addition, complex PTFE components are produced by isostatic and automatic moulding processes.

Our high quality products are supplied for some of the world’s most prestigious projects and used across many business areas including chemical, medical, fluid handling and aerospace.

Our moulding technologies are enhanced by first class technical support, material advice and product and mould design.

Compression Moulding

We offer a comprehensive service for the compression moulding of PTFE and melt fluoropolymers suitable for modern day machining centres.

Using our Fluorinoid® Company materials register of over 500 grades and our in-house blending facilities, we work with customers to develop and blend grades to suit specific applications.

Service

  • Full traceability on all material under ISO 9001:2000
  • In-house tensile strength and elongation testing
  • Etching and bonding service
  • Prototyping available
  • Over 1500 moulding tools available from our continually expanding range
  • Materials are conditioned and stress-relieved to ensure optimum quality for modern day machining centres

PTFE Compression Moulded Rod & Tube

  • Moulded Rods 3mm - 50mm Ø up to 2000mm length
  • Moulded Rods 1mm - 1500mm Ø at various lengths
  • Moulded Tubes 20mm - 1500mm Ø at various lengths
  • A unique special process to produce lengths of 2000mm of low stress material for high precision machining within a narrow tolerance band

(Melt Fluoropolymers)
Hot Compression Moulded Rod & Tube

  • Rods 28mm - 100mm Ø up to 200mm length
  • Rods 51mm - 100mm Ø up to 100mm length
  • Rods 101mm - 200mm Ø up to 50mm length
  • Tubes 25mm - 100mm (I.D) x 50mm - 150mm Ø (O.D) up to 200mm length
  • Tubes 10mm - 250mm (I.D) x 125mm- 300mm Ø (O.D) up to 150mm length
  • Tubes 275mm - 500mm (I.D) x 350mm- 550mm Ø (O.D) up to 100mm length
  • Tubes 525mm - 850mm (I.D) x 600mm- 940mm Ø (O.D) up to 60mm length
  • Sheet 300mm x 300mm width up to 40mm thickness

Injection Moulding

This manufacturing technique for making parts is one of the most common methods of production. The molten plastic is injected at high pressure into a mould that is the inverse of the products shape.

Our wide range of specially modified injection moulding machines provides the capabilities to design and manufacture a wide variety of customer components from thermoplastics and fluoropolymers including PFA, FEP, PCTFE, PEEK, ETFE, ECTFE, PES, PAI PPS, LCP, TPE (Thermo plastic elastomers) Nylon, Acetal.

Optimized for cost and reliability, our facilities mould complex shapes in high volume production and/or one-off bespoke parts for a specific application. Using our unique tooling system we can supply samples and prototypes prior to production.

Machine Modification

  • Special barrels and screws to prevent machine corrosion when processing fluoropolymers
  • Special heaters to allow proving of materials with temperatures in excess of 400°C
  • Desiccant dryers to remove all traces of moisture from normal and hygroscopic moulding
  • High temperature oil heaters for better control and ensures moulds are heated and maintained at the correct temperature

Capabilities

  • Insert and Over moulding (moulding to another material e.g. metal)
  • Semi-finished Near Shape moulding
  • Moulding machine capacity: 25-220 tonne clamp force
  • Shot weights: 0.5gram - 500 gram
  • Ability to process materials in excess of 400°C
  • Post Moulding

We can offer the following service

  • Ultrasonic welding
  • Machining
  • Assembling
  • Printing

Isostatic Moulding

Isostatic moulding, originally developed for the manufacture of ceramics, can provide the solution to enable intricate and contoured shapes to be produced with little or no machining. We have the ability to produce high quality, large and complex shapes in PTFE which, to date; have been virtually impossible to produce other than by extensive machining and fabrication.
The Isostatic process is ideally suited for repetitive batch manufacture of PTFE components and both insert and outsert moulding to combine the corrosion resistance of the PTFE with the strength of metal.

There are two types of processes; dry bag and wet bag and both methods incorporate the cold compaction of PTFE at high pressure, followed by sintering at temperatures of around 400ºC (752ºF).

DRY BAG

This process is normally carried out using a mould in a hydraulic press.

Advantages

  • Dramatic savings on material usage
  • High Quality PTFE Grade A Type 1
  • Repeatability
  • High out-put compared with wet bag moulding and compression moulding
  • More intricate shapes
  • Cleaner process

WET BAG

The process involves a flexible elastomeric mould which is pressurised within a hydrostatic pressure chamber.

Advantages

  • Large sizes
  • Longer lengths with the same pressure throughout the billet
  • Cost-effective tooling

TYPICAL ISOSTATIC PRODUCTS

Corrosion Industry

  • Pipe & column liners (up to 600mm dia)
  • Pipe fittings (tees, elbows & reducers
  • Nozzles and dip pipes
  • Valve liners (diaphragm)
  • Bellows
  • Pump liners (centrifugal, screw)
  • Impellers, agitators and mixer paddles

Electrical Industry

  • High voltage insulators

Medical & Semiconductor Industries

  • Tanks & containers